Tools Needed

Metric socket set with extensions · Torque wrench · Primary clutch puller tool · Snap ring pliers · Impact wrench · Breaker bar · Magnetic parts tray

Quick First Checks

• Remove CVT cover and inspect belt for glazed edges or missing teeth
• Check engine idle speed — must be below 1300 RPM to prevent clutch drag
• Inspect primary clutch rollers for flat spots or debris buildup
• Verify the one-way bearing rotates freely in one direction
• Check front and rear prop shaft U-joints for excessive needle bearing play
• Clean clutch sheaves with a green Scotch-Brite pad and brake cleaner
• Inspect the secondary clutch 'buttons' or 'rollers' for metal-on-metal wear

Repair Steps

• 1. Remove and Inspect CVT Cover

  Unbolt the outer CVT plastic cover and inspect for belt debris or wear marks inside. Look for scuffing on the plastic interior, which indicates the belt is slapping due to low tension.

  ⚠ Always perform this check with the engine cold to avoid burns from the clutch housing.

• 2. Measure CVT Belt Width

  Using digital calipers, measure the belt width at multiple points against the service manual specifications. A belt worn beyond the service limit will cause the jumping issues described.

  ⚠ Ensure the engine is off and the ignition key is removed before handling the belt.

• 3. Primary Clutch Inspection

  Use a clutch puller tool to remove the primary clutch and disassemble it to inspect the rollers and bushings. Check for flat spots on the rollers and ensure the spring is not broken.

  ⚠ Wear safety glasses; the clutch spring is under high tension and can be dangerous if released improperly.

• 4. Check Secondary Clutch Sheave Operation

  Manually compress the secondary clutch to ensure it moves smoothly throughout its full travel. If it binds or chatters, the helix or bushings require cleaning and lubrication.

  ⚠ Keep fingers clear of the sheave contact area to avoid pinching.

• 5. Inspect Output Shaft and Flange

  Remove the drive shaft flange and inspect the teeth on both the shaft and the flange. Any rounding of the teeth indicates they are skipping, necessitating immediate replacement of the shaft/flange.

  ⚠ Secure the ATV on jack stands; do not trust the parking brake alone when working on drivetrain components.

• 6. Clean Clutch Components

  Use non-chlorinated brake cleaner to remove all belt dust and oil residue from the sheaves. Contamination is a leading cause of belt slip and erratic clutch behavior.

  ⚠ Work in a well-ventilated area and avoid inhaling brake dust.

Avoid These Mistakes

• ✕ Replacing only the belt without cleaning the sheaves of oily residue
• ✕ Using grease on the clutch bushings instead of recommended dry lubricants
• ✕ Forgetting to index the clutch components during reassembly
• ✕ Ignoring the condition of the drive shaft splines when performing a clutch overhaul

Prevent Recurrence

• Clean the CVT housing intake and exhaust vents regularly to prevent dust buildup
• Perform a dry-clutch inspection every 500 miles to check for weight wear
• Avoid holding the ATV stationary on steep inclines using the throttle
• Use OEM Arctic Cat belts to ensure proper compound and dimensions